Influence of nanostructured CVD diamond coatings on dust emission and machinability of SiC particle-reinforced metal matrix composite

This paper reports on experimental test program to study the effect of the coating structure associated with the machining of metal matrix composite (MMC). The composite materials investigated were respectively a 5%, 15% and 25% by volume SiC particle-reinforced A2009 aluminum alloy. The machining of these materials is indeed very difficult due to the abrasive effect of reinforcement upon the cutting tool. In this work, the ability of coated tools with nanostructured CVD diamond coatings to cut MMC components is discussed during dry machining. The performances of three different structures of CVD diamond coating are then considered using classical parameters (cutting forces, tool life, residual stress) and innovative criterion such as dust emission. The results show that in spite of their similar thickness, the coatings have various performances. The tool life was varied in a ratio of 1 to 6 irrespectively to the cumulative wear evolution which was monitored in situ with a power measurement and quantified ex situ using a white light interferometer. (C) 2009 Elsevier B.V. All rights reserved.